Okay, current plan (I forgot it's fiberglass!!) is to just use floxed epoxy to build up the area inside the channel, sand the **** out of things and then even out the width of the new, adjusted flange.

Engine work was fun, but time to get back into the epoxy rhythms I guess.

Why not tape some corrugated cardboard (or a similar spacer, maybe 3/8" thick) to the unfinished side of that flange. Cover it in packing tape with a nice radius to the front of the inside portion of the flange and apply wax as a mold release.

Then lay-up a new flange over your spacer. Trim off the current flange, add a layer of glass where you removed the flange, fill and sand to your taste, and voila, you're done.

You will want to cover the flox with two layers of glass once you have sanded to the dimensions you like. The glass will bond it to the other fiberglass of the cowl making it one strong piece. Make sure it laps over your build up and out 3/4-1" out onto the cowl fiberglass. This overlap will need to be scuffed beforehand.

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